Fall protection system

ABSTRACT

A fall protection system is used in constructing a vertical wall comprising multiple stacked courses. The fall protection system includes a plurality of anchors adapted for engaging the wall and forming respective fixed points of support. A plurality of posts are secured by respective anchors, and are designed to extend above a leading edge of the wall during construction. A fence extends between adjacent posts to provide a protective barrier between a working level adjacent the wall and the leading edge.

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

This invention relates generally to fall protection in the constructionindustry, and more specifically to a system especially designed for useduring installation of dry-stacked block retaining walls. In manycommercial applications, these walls may reach 15 or more feet inheight. The unguarded leading edge of the wall is a safety hazard. Thepresent invention effectively addresses this hazard in a manner which isboth time and cost efficient, and which protects the safety of workersconstructing the wall consistent with federal guidelines established byOSHA.

Each year, falls consistently account for the greatest number offatalities in the construction industry. Events surrounding these typesof accidents often involve a number of factors, including unstableworking surfaces, misuse of fall protection equipment, and human error.Studies have shown that the use of guardrails and other fencing atunprotected leading edges can prevent many deaths and injuries fromfalls. Despite the promulgation of the OSHA Construction Standards in1971, fall accidents resulting in injuries and fatalities continue tooccur at construction sites.

In constructing commercial retaining walls, OSHA guidelines for fallprotection are often disregarded. Given the typical nature of thesurroundings and the changing elevation of the wall, common safetymeasures practiced in other construction fields require more time andeffort to implement, and are generally too costly and impractical. Fixedrailing and other safety supports do not conveniently adjust with therising elevation of the wall. Other measures, such as tethering, arealso cumbersome and inconvenient, and may themselves present furthersafety hazards.

SUMMARY OF INVENTION

Therefore, it is an object of the invention to provide a fall protectionsystem which is especially useful in the installation of dry-stackedblock retaining walls.

It is another object of the invention to provide a fall protectionsystem which meets federal guidelines established by OSHA.

It is another object of the invention to provide a fall protectionsystem which is quickly assembled and raised during construction of thewall.

It is another object of the invention to provide a fall protectionsystem which is entirely removable from the wall once construction iscompleted.

It is another object of the invention to provide a fall protectionsystem which does not damage the wall.

It is another object of the invention to provide a fall protectionsystem which anchors directly and entirely to the wall.

It is another object of the invention to provide a safety method forfall protection used during construction of a vertical wall.

These and other objects of the present invention are achieved in thepreferred embodiments disclosed below by providing a fall protectionsystem for use in constructing a vertical wall comprising multiplestacked courses. The fall protection system includes a plurality ofanchors adapted for engaging the wall and forming respective fixedpoints of support. A plurality of posts are secured by respectiveanchors, and are designed to extend above a leading edge of the wallduring construction. Means extending between adjacent posts are providedto create a protective barrier between a working level adjacent the walland the leading edge.

According to another preferred embodiment, each of the plurality ofanchors comprises a rigid anchor plate. The anchor plate has a proximalend adapted for being sandwiched between adjacent wall courses, and adistal end adapted for projecting from the face of the wall.

According to another preferred embodiment, the proximal end of theanchor plate defines a catch adapted for engaging a course connectorlocated between the adjacent wall courses.

According to another preferred embodiment, the catch defines a pin slotadapted for receiving a vertical pin located between the adjacent wallcourses.

According to another preferred embodiment, the distal end of the anchorplate defines a post hole designed to receive the post.

According to another preferred embodiment, the distal end of the anchorplate further defines a tool hole designed to receive a plate removaltool.

According to another preferred embodiment, an anchor basket depends fromthe post hole, and receives a bottom end of the post to hold the post ata fixed height relative to the wall.

According to another preferred embodiment, the anchor basket isremovably received within the post hole.

According to another preferred embodiment, the means for creating aprotective barrier comprises at least one horizontal cable line.

According to another preferred embodiment, the means for creating aprotective barrier comprises a flexible grid wall.

According to another preferred embodiment, at least one of the pluralityof posts is marked with gradations.

In another embodiment, the invention is a safety method for fallprotection used during construction of a vertical wall comprisingmultiple stacked courses. The safety method includes the steps oflocating a plurality of anchors between two adjacent wall courses. Theanchors are spaced apart along the wall at a base elevation, and formrespective fixed points of support. A plurality of posts are thensecured to respective anchors. The posts extend vertically from the baseelevation above a leading edge of the wall during construction. Aprotective barrier is then located between adjacent posts, and between aworking level adjacent the wall and the leading edge.

According to another preferred embodiment, the safety method includeslocating a second plurality of anchors at a raised elevation above thebase elevation. The first and second plurality of anchors reside insubstantial vertical alignment and cooperate to secure respective posts.

According to another preferred embodiment, the second plurality ofanchors is located at least two courses above the first plurality ofanchors at the base elevation.

According to another preferred embodiment, the safety method includesremoving and replacing the anchors to raise the base elevation duringconstruction.

According to another preferred embodiment, the safety method includesreleasably securing each anchor to a course connector located betweenadjacent courses of the wall.

According to another preferred embodiment, the safety method includesremoving the anchors, posts, and protective barrier after constructionof the wall.

According to another preferred embodiment, the safety method includeslocating the anchors no more than 8 feet apart along the wall at thebase elevation.

According to another preferred embodiment, the safety method includesextending the posts at least 3 feet above the leading edge of the wall.

BRIEF DESCRIPTION OF THE DRAWINGS

Some of the objects of the invention have been set forth above. Otherobjects and advantages of the invention will appear as the descriptionproceeds when taken in conjunction with the following drawings, inwhich:

FIG. 1 is an environmental perspective view of a fall protection systemaccording to one preferred embodiment of the present invention;

FIG. 2 is a perspective view of the anchor plate positioned on a lowercourse wall block;

FIG. 3 is a top view of the anchor plate;

FIG. 4 is a view demonstrating insertion of the post basket into thepost hole of the anchor plate;

FIG. 5 shows the post basket inserted in the post hole and dependingfrom the anchor plate;

FIG. 6 is a fragmentary perspective view of a vertical wall with thebase elevation anchor plate and post basket installed;

FIG. 7 is a fragmentary perspective view of the wall showing the secondanchor plate installed in vertical registration with the first;

FIG. 8 is a fragmentary perspective view of the wall showing the firstand second anchor plates installed, and additional block courses laidabove the second plate;

FIG. 9 is a fragmentary perspective view the wall with the safety postfed through the post opening of the second anchor plate and into thepost basket of the first anchor plate;

FIG. 10 is a view showing the face of the wall, and demonstratingmovement of the safety post from a first elevation to a raised elevationas the wall is constructed; and

FIG. 11 is an environmental perspective view of a fall protection systemaccording to a second preferred embodiment of the present invention;

DESCRIPTION OF THE PREFERRED EMBODIMENT AND BEST MODE

Referring now specifically to the drawings, a fall protection systemaccording to the present invention is illustrated in FIG. 1, and showngenerally at reference numeral 10. The fall protection system 10 isespecially applicable for use during construction of a verticalretaining wall 11 comprising courses of dry-stacked concrete block 12.The system 10 is quickly and conveniently raised during construction asthe wall height increases. When the wall 11 is completed, the system isreadily removed without damage to the wall or various components of thesystem 10.

Referring to FIGS. 1, 2, and 3, the system 10 utilizes rigid steelanchor plates 14 which project from a face of the wall 11 and securerespective safety posts 15. The posts 15 extend vertically above aleading edge 16 of the wall 11, and cooperate to carry a flexible gridfence 18 or other protective barrier. The fence 18 extends between aworking level adjacent the wall 11 and the leading edge 16 to protectthe safety of workers as the wall blocks 12 are stacked and set duringconstruction. Typical wall blocks 12, such as those described in priorU.S. Pat. No. 6,615,561 to Keystone Retaining Wall Systems, weigh asmuch as 80 pounds and can be relatively difficult to handle. Thecomplete disclosure of this patent is incorporated herein by thisreference.

As shown in FIGS. 2 and 3, each plate 14 has a flat proximal end 14Adesigned to sandwich between upper and lower blocks 12 in adjacentstacked courses, and a generally flat distal end 14B defining a postopening 21 for receiving and securing the safety post 15. The anchorplates 14 are first installed at a base elevation approximately 3-4courses above the ground. The proximal end 14A of each plate 14 definesa pin slot 22 or other catch formed to receive a course connecting pin24 projecting vertically from a top of the lower course block 12. As thelower course of block 12 is laid, the anchor plates 14 are installedapproximately 8 feet apart from each other along the course at the baseelevation. The upper course of block 12 is then stacked on the lowercourse over respective proximal ends 14A of the anchors plates 14. Eachupper course block 12 has complementary pin openings arranged to receivethe course connecting pins 24 projecting from the lower course blocks12, as described in the '561 Patent. The course connecting pin 24located in the pin slot 22 prevents the anchor plate 14 from pullingoutward away from the face of the wall 11. The pin slot 22 is formed inthe side of the anchor plate 14 adjacent the rear edge, as best shown inFIG. 3. The weight of the stacked block 12 above the anchor plate 14further secures the plate between the courses, and prevents inadvertentshifting and rotation. In an alternative embodiment (not shown), theproximal end of the anchor plate has no pin slot, and simply engages anintegrally-formed knuckle or other block structure sufficient to securethe plate between the courses. In yet another embodiment, for retainingwalls without existing mechanical course connectors, separate anchorpins may be installed between the courses in order to secure respectiveanchor plates.

Referring to FIGS. 4, 5, and 6, once the anchor plate 14 is installed atthe base elevation, a supporting post basket 25 is inserted into thepost opening 21 formed with the distal end 14B. The post basket 25 has agenerally U-shaped body 26 which depends from the anchor plate 14, andopposing outward flanges 27 and 28 which support the basket 25 in thepost opening 21.

After inserting post baskets 25 in each of the base elevation anchorplates 14, an additional 3-5 courses of block are stacked as the wall 11is raised. A second row of spaced anchor plates 14′ are then placed insubstantial vertical registration above the first anchor plates 14 (SeeFIG. 7). The second anchor plate 14′ is installed in a manner identicalto that previously described, except that no post basket 25 is insertedin the post opening 21. An additional 2-3 courses of block 12 are thenstacked above the second row of anchor plates 14′, as shown in FIG. 8.Once the working level elevation exceeds 6 feet, the safety posts 15 arefed through the post openings 21′ in the second row of anchor plates 14′and into the post baskets 25 of the base elevation anchor plates 14, asshown in FIG. 9. Preferably, the safety posts 15 are marked withgradations 31 to readily determine the length of post extending abovethe leading edge 16 of the wall 11 and working level. The posts 15 mayalso include hooks 32, shown in FIG. 1, or other clamping means forattaching the flexible grid fence 18. According to OSHA guidelines, theposts 15 must support at least 42-inches of protective fencing above theworking level. The first and second rows of anchor plates 14 and 14′cooperate to secure the posts 15 to the face of the wall 11.

As the height of the wall 11 increases, the fall protection system 10must be raised as prescribed by OSHA guidelines. The system 10 is raisedby separately lifting and removing each safety post 15 from its firstand second anchor plates 14 and 14′. The post basket 25 of the firstanchor plate 14 is removed and inserted into the post hole 21′ of thesecond anchor plate 14′. The first anchor plate 14 is then removed usinga hammer or other suitable tool. By striking the anchor plate 14 at ornear point 35 shown in FIG. 2, the plate 14 shifts and rotates away fromthe course connecting pin 24. A second tool, such as a screw driver, maythen be inserted into a tool hole 36 and employed to help pull the plate14 away from the wall 11. Once removed, the first anchor plate 14 isreplaced in the wall 11 above the second anchor plate 14′ and insubstantial vertical alignment for receiving the safety post 15. Thesafety posts 15 scale the face of the wall 11, as indicated in FIG. 10,as the wall height increases—the goal being to maintain at least42-inches of protective fence 18 above the working level at all times.

In the embodiment of FIG. 11, the fall protection system 50 utilizes anumber of vertically-spaced horizontal steel cables 52 extending betweenthe posts 54 to create a safety barrier between the working level andleading edge of the wall 55. All other elements, features, andinstallation of the fall protection system 50 are as previouslydescribed with regard to the system 10.

A fall protection system is described above. Various details of theinvention may be changed without departing from its scope. Furthermore,the foregoing description of the preferred embodiment of the inventionand best mode for practicing the invention are provided for the purposeof illustration only and not for the purpose of limitation—the inventionbeing defined by the claims.

1. A fall protection system for use in constructing a vertical wallcomprising multiple stacked courses, said fall protection systemcomprising: a plurality of anchors adapted for engaging the wall andforming respective fixed points of support; a plurality of posts securedby respective anchors, and designed to extend above a leading edge ofthe wall during construction; and means extending between adjacent poststo create a protective barrier between a working level adjacent the walland the leading edge.
 2. A fall protection system according to claim 1,wherein each of said plurality of anchors comprises a rigid anchorplate, said anchor plate having a proximal end adapted for beingsandwiched between adjacent wall courses, and a distal end adapted forprojecting from the face of the wall.
 3. A fall protection systemaccording to claim 2, wherein the proximal end of said anchor platedefines a catch adapted for engaging a course connector located betweenthe adjacent wall courses.
 4. A fall protection system according toclaim 3, wherein said catch comprises a pin slot adapted for receiving avertical pin located between the adjacent wall courses.
 5. A fallprotection system according to claim 2, wherein the distal end of saidanchor plate defines a post hole designed to receive said post.
 6. Afall protection system according to claim 5, wherein the distal end ofsaid anchor plate further defines a tool hole designed to receive aplate removal tool.
 7. A fall protection system according to claim 5,and comprising an anchor basket depending from said post hole, andreceiving a bottom end of said post to hold said post at a fixed heightrelative to the wall.
 8. A fall protection system according to claim 7,wherein said anchor basket is removably received within said post hole.9. A fall protection system according to claim 1, wherein said means forcreating a protective barrier comprises at least one horizontal cableline.
 10. A fall protection system according to claim 1, wherein saidmeans for creating a protective barrier comprises a flexible grid wall.11. A fall protection system according to claim 1, wherein at least oneof said plurality of posts is marked with gradations.
 12. In a verticalwall comprising multiple stacked courses, the invention comprising afall protection system used during construction of the wall, the fallprotection system comprising: a plurality of spaced anchors engaging thewall and forming respective fixed points of support; a plurality ofposts secured by respective anchors, and extending above a leading edgeof the wall during construction; and means extending between adjacentposts to create a protective barrier between a working level adjacentthe wall and the leading edge.
 13. A safety method for fall protectionused during construction of a vertical wall comprising multiple stackedcourses, said safety method comprising the steps of: locating aplurality of anchors between two adjacent wall courses, the anchorsbeing spaced apart along the wall at a base elevation and formingrespective fixed points of support; securing a plurality of posts torespective anchors, the posts extending vertically from the baseelevation above a leading edge of the wall during construction; andlocating a protective barrier between adjacent posts, and between aworking level adjacent the wall and the leading edge.
 14. A safetymethod according to claim 13, and comprising locating a second pluralityof anchors at a raised elevation above the base elevation, the first andsecond plurality of anchors residing in substantial vertical alignmentand cooperating to secure respective posts.
 15. A safety methodaccording to claim 14, wherein the second plurality of anchors islocated at least two courses above the first plurality of anchors at thebase elevation.
 16. A safety method according to claim 13, andcomprising removing and replacing the anchors to raise the baseelevation during construction.
 17. A safety method according to claim13, and comprising releasably securing each anchor to a course connectorlocated between adjacent courses of the wall.
 18. A safety methodaccording to claim 13, and comprising removing the anchors, posts, andprotective barrier after construction of the wall.
 19. A safety methodaccording to claim 13, and comprising locating the anchors no more than8 feet apart along the wall at the base elevation.
 20. A safety methodaccording to claim 13, and comprising extending the posts at least 3feet above the leading edge of the wall.